S-900
Maintenance
Training Guide
Course No. 7216700
Training Guide
Course No. 7216700
Introduction
Table of Contents
Manual/Conventions Review
Course Objectives
Classroom Safety
Final Certification
Course Critique
S-900 Operations and Programming
Manual P/N 7216701 (Revision C)
Table of Contents
Introduction
Table of Contents ........................................................................................... iii
Manual/Conventions Review .............................................................................v
Course Objectives ........................................................................................... vi
Classroom Safety ........................................................................................... vii
Final Certification ............................................................................................ xi
Course Critique ............................................................................................. xiii
Module 1
Subsystem Description
Lesson 1.1 Safety ........................................................................................ 1-1
Lesson 1.2 Dispensing System Components .................................................. 1-23
Lesson 1.3 Power Distribution ...................................................................... 1-31
Lesson 1.4 Pneumatic Distribution ................................................................ 1-37
Lesson 1.5 Servo System ............................................................................. 1-47
Lesson 1.6 Vision System ............................................................................ 1-51
Lesson 1.7 Valve Control ............................................................................. 1-61
Lesson 1.8 Height Sensor ............................................................................ 1-65
Lesson 1.9 Tactile Sensor ............................................................................ 1-71
Lesson 1.10 Scale ....................................................................................... 1-73
Lesson 1.11 Conveyor ................................................................................. 1-75
Lesson 1.12 Substrate Heat ......................................................................... 1-91
Lesson 1.13 Bulk Feed Supply ...................................................................... 1-97
Module 2
Equipment Servicing
Lesson 2.1 Camera Focus Adjustment and Calibration ..................................... 2-1
Lesson 2.2 Service Station Height Adjustment ................................................ 2-7
Lesson 2.3 Scale Calibration ......................................................................... 2-9
Lesson 2.4 Z-head Counterbalance Force Adjustment .................................... 2-15
Lesson 2.5 Mechanical Height Sensor Adjustment .......................................... 2-19
Lesson 2.6 Tactile Sensor ............................................................................ 2-21
Lesson 2.7 Conveyor Setup ......................................................................... 2-25
Lesson 2.8 Adjusting the Lift Table Speed ..................................................... 2-37
Lesson 2.9 Substrate Heaters ...................................................................... 2-41
Lesson 2.10 Adjusting the Board Sensors ...................................................... 2-57
Lesson 2.11 Pneumatic Adjustments............................................................. 2-61
Lesson 2.12 Linear Encoder Adjustment........................................................ 2-73
Lesson 2.13 CAN Flash Procedure ................................................................ 2-81
Table of Contents
iii
Module 3
Preventive Maintenance
Lesson 3.1 Preventive Maintenance Schedule ................................................. 3-1
Lesson 3.2 Replacing Consumables ............................................................... 3-3
Lesson 3.3 Draining the Water Trap .............................................................. 3-9
Lesson 3.4 Removing the Axis Covers ........................................................... 3-11
Lesson 3.5 Lubricating the Cables ................................................................ 3-15
Lesson 3.6 Lubricating the X-Y Linear Guides ................................................ 3-19
Lesson 3.7 Tensioning the Cables................................................................. 3-23
Lesson 3.8 Tensioning the Conveyor Belts .................................................... 3-25
Module 4
Troubleshooting
Lesson 4.1 Troubleshooting .......................................................................... 4-1
Module 5
Parts Replacement
Lesson 5.1 Removing and Replacing the Conveyor Belts.................................. 5-1
Lesson 5.2 Removing and Replacing the Conveyor Motors ............................... 5-5
Lesson 5.3 Removing and Replacing the X/Y Drive Motors............................... 5-9
Lesson 5.4 Removing and Replacing the Camera ........................................... 5-13
Lesson 5.5 Removing and Replacing Height Sensor Probe .............................. 5-17
Lesson 5.6 Removing and Replacing Fuses ................................................... 5-19
Lesson 5.7 Removing and Replacing the Laser Height Sensor ......................... 5-25
Lesson 5.8 Removing and Replacing the Vacuum Generators.......................... 5-29
Lesson 5.9 Removing, Replacing, and Reconfiguring the USB Hub .................. 5-35
Lesson 5.10 Removing, Replacing, and Reconfiguring the Ethernet Adapter ..... 5-39
Lesson 5.11 Removing and Replacing the Main PWA ...................................... 5-45
Lesson 5.12 Removing and Replacing the Pneumatic Control PWA .................. 5-49
Lesson 5.13 Removing and Replacing the Single Dispense Head Control
(SDHC) PWA .............................................................................................. 5-53
Lesson 5.14 Removing and Replacing the Servo Power PWA .......................... 5-57
Lesson 5.15 Removing and Replacing the XYZ Servo Amp PWA ...................... 5-61
Lesson 5.16 Removing and Replacing the Z Drive Cable ................................. 5-65
Lesson 5.17 Removing and Replacing the X/Y Drive Cable .............................. 5-75
Lesson 5.18 Removing and Replacing the Linear Encoder ............................... 5-97
Lesson 5.19 Removing and Replacing the Power Manager ............................ 5-107
Lesson 5.20 Removing and Replacing the Heater/Conveyor Controller ........... 5-111
Lesson 5.21 Removing and Replacing the Electronic/Pneumatic Controllers ... 5-115
Lesson 5.22 Removing and Replacing the Scale Assemblies .......................... 5-119
iv
Table of Contents
Manual/Conventions Review
Manual Review:



S-9XX Installation, Operations, and Maintenance Manual
Fluidmove for Windows User Guide
DP-3000/DV-6000/DV-7000/DJ-2000/DJ-9000 Valve Manuals
Conventions Review:











Buttons
Cautions
Commands
Filenames
Glossary Terms
Help
Labels
Notes
Tips
Typed Commands
Warnings
Layouts Review:






Appendixes
Glossaries
Indexes
Manual Contents
Manual Sections
Table of Contents
Manual/Conventions Review
v
Course Objectives
1.0
Identify S-900 Series Dispensing System features and precautions.
2.0
Perform equipment calibration, adjustment, and service on S-900 Series Dispensing
System components.
3.0
Perform preventive maintenance procedures on S-900 Series Dispensing Systems.
4.0
Perform troubleshooting procedures on S-900 Series Dispensing Systems.
5.0
Replace components on S-900 Series Dispensing Systems.
vi
Course Objectives
Classroom Safety
A. Student Safety
1.
Any time a student or an instructor has apprehension concerning his/her personal
safety or that of another, he/she will stop the evolution to clarify the situation or
procedure and receive additional instruction as appropriate.
2.
The instructor is responsible for maintaining situational awareness and shall remain
alert to signs of fatigue or exhaustion that may impair safe completion of the training
lesson.
 If the instructor deems appropriate, he/she will immediately stop the training,
identify the problem, and make a determination to continue or discontinue training.
 The instructor shall remain alert to any unusual behavior and will immediately take
appropriate action to ensure the student's safety.
3.
The instructor will make sure that the following guidelines are followed to ensure
student safety:

All safety warning labels will be located and identified before equipment operation.

The system will always be operated with the safety interlocks ON.

In case of a system malfunction, the Emergency Machine Off (EMO) button will
immediately be activated.

Operator will not wear loose clothing or jewelry.

Operator will tie back long hair.

Operator will wear safety glasses.

Operator shall not touch the heater area under the conveyor.

Material Safety Data Sheets (MSDS) will be reviewed for all fluids dispensed.

MSDS recommendations for the proper disposal of syringes and fluids will be
followed.

Only qualified personnel will perform maintenance and troubleshooting procedures.
Classroom Safety
vii
B. Safety Review
1.
Emergency Evacuation

Situations
- Fire or Explosion
- Chemical Spill
- Earthquake

Actions to Be Taken
- Small Fire – Notify nearest Asymtek employee of fire, who will in turn take
appropriate action.
- Small Chemical Spill – Supervisors will be contacted immediately. Visitors should
notify nearest Asymtek employee of spill, who will in turn take appropriate
action.
- Large Fire or Large Chemical Spill – Call 911.
 Notify Receptionist for paging evacuation.
 Notify Human Resources of evacuation. They will ring bell to alert people to
evacuate building.
2.
3.
4.
Evacuation Notification
A page announcement will let everyone know to evacuate the building.

The bell will be ringing in a consistent long ring.
Evacuation Procedures

Use the closest exit.

Walk, don’t run.

Provide assistance for injured persons.

Assemble in the Northeast section of the parking lot.

Employees are responsible for ensuring visitors exit the building and assemble in
the appropriate location.

Do not return to building until approved by management, Police Department or Fire
Department.
Evacuation Routes

viii

The instructor and students will follow local evacuation routes.
Classroom Safety
C. Building Fire Alarms
1.
Asymtek buildings are equipped with fire alarms.
2.
Follow evacuation procedures if evacuation is necessary.
D. Emergency Reporting Procedures
E.
F.
1.
The instructor is responsible for assessing and reporting emergency situations in
accordance with Asymtek policy.
2.
If the instructor is unavailable, visitors should contact the nearest Asymtek employee,
who will in turn take appropriate action.
Offsite Training (Outside of Asymtek, Carlsbad)
1.
The instructor will ensure that emergency reporting and evacuation procedures are
followed in accordance with building policy.
2.
The instructor will be aware of emergency evacuation routes.
System Protection
1.
2.
The instructor will make sure that the following guidelines are followed to ensure
system protection:

A grounding strap will be worn when necessary.

Special care will be taken when dispensing with caustic or conductive fluids.
Appropriate action will immediately be taken to clean up and contain spills. If fluid
gets into the internal portions of the machine, maintenance will be immediately
contacted.

Work area will be kept clean.

All recommended maintenance will be followed.

Parts that have fallen into the dispensing system will be immediately removed.

Any fluid spills will be immediately cleaned.
Additional safety notes can be referenced in the safety section of the appropriate
equipment manual.
Classroom Safety
ix
S-900 SERIES M AINTENANCE
COURSE NO. 7216600
Final Certification
STUDENT NAME:
ID#
INSTRUCTOR NAME:
FACTORY:
DATE(S):
TRAINING SITE:
Module 1 Subsystem Description
1.1
Safety
1.2
Dispensing System Components
1.3
Power Distribution
1.4
Pneumatic Distribution
1.5
Servo System
1.6
Vision System
1.7
Valve Control
1.8
Height Sensor
1.9
Tactile Sensor
1.10
Scale
1.11
Conveyor
1.12
Substrate Heat
1.13
Bulk Feed Supply
Module 2 Equipment Servicing
2.1
Camera Focus Adjustment and Calibration
2.2
Service Station Height Adjustment
2.3
Scale Calibration
2.4
Z-Head Counterbalance Force Adjustment
2.5
Mechanical Height Sensor Adjustment
2.6
Tactile Sensor
2.7
Conveyor Setup
2.8
Adjusting the Lift Table Speed
2.9
Substrate Heaters
2.10
Adjusting the Board Sensors
2.11
Pneumatic Adjustments
2.12
Linear Encoder Adjustment
2.13
CAN Flash Procedure
Final Certification
Instructor
Student
Instructor
Student
xi
S-900 SERIES M AINTENANCE
FINAL CERTIFICATION (CONTINUED)
Module 3 Preventive Maintenance
3.1
Preventive Maintenance Schedule
3.2
Replacing Consumables
3.3
Draining the Water Trap
3.4
Removing the Axis Covers
3.5
Lubricating the Cables
3.6
Lubricating the X-Y Linear Guides
3.7
Tensioning the Cables
3.8
Tensioning the Conveyor Belts
Module 4 Troubleshooting
4.1
Student
Instructor
Student
Instructor
Student
Troubleshooting
Module 5 Parts Replacement
xii
Instructor
5.1
Removing and Replacing the Conveyor Belts
5.2
Removing and Replacing the Conveyor Motors
5.3
Removing and Replacing the X/Y Drive Motors
5.4
Removing and Replacing the Camera
5.5
Removing and Replacing the Height Sensor Probe
5.6
Removing and Replacing Fuses
5.7
Removing and Replacing the Laser Height Sensor
5.8
Removing and Replacing the Vacuum Generators
5.9
Removing, Replacing, and Reconfiguring the USB Hub
5.10
Removing, Replacing, and Reconfiguring the Ethernet Adapter
5.11
Removing and Replacing the Main PWA
5.12
Removing and Replacing the Pneumatic Control PWA
5.13
Removing and Replacing the Single Dispense Head Control PWA
5.14
Removing and Replacing the Servo Power PWA
5.15
Removing and Replacing the XYZ Servo Amp PWA
5.16
Removing and Replacing the Z Drive Cable
5.17
Removing and Replacing the X/Y Drive Cable
5.18
Removing and Replacing the Linear Encoder
5.19
Removing and Replacing the Power Manager
5.20
Removing and Replacing the Heater/Conveyor Controller
5.21
Removing and Replacing the Electronic/Pneumatic Controllers
5.22
Removing and Replacing the Scale Assemblies
Final Certification
Course Critique
The objective of this critique is to improve the quality and effectiveness of the future training of this
course. Please provide detailed examples whenever possible.
PLEASE PRINT THE FOLLOWING INFORMATION
COURSE START DATE:
__________________________________________________________
CLASS LOCATION:
__________________________________________________________
COURSE NAME:
__________________________________________________________
INSTRUCTOR NAME:
__________________________________________________________
EMPLOYEE WWID#:
__________________________________________________________
STUDENT NAME (Optional): __________________________________________________________
COURSE EVALUATION (Please circle your choice.)
1.
2.
3.
4.
5.
6.
7.
8.
All of the learning objectives were discussed and met.
The hands on activities were useful and will support my
efforts on the job.
The topics were presented in a manner that was easily
understood.
The content of this course prepared me to do my job.
Text and materials will support me in doing my job.
The materials were current.
I was able to understand the materials.
Spaces, equipment, manual and other documents were
available as needed.
Strongly
Disagree
1
Disagree
Neutral
Agree
2
3
4
Strongly
Agree
5
1
2
3
4
5
1
2
3
4
5
1
1
1
1
2
2
2
2
3
3
3
3
4
4
4
4
5
5
5
5
1
2
3
4
5
Disagree
Neutral
Agree
2
3
4
Strongly
Agree
5
1
2
3
4
5
1
2
3
4
5
FACILITIES EVALUATION (Please circle your choice.)
1.
2.
3.
Room and lab space made learning easy.
The machine used for practice allowed me to learn and
perform the tasks.
Supplies needed for hands-on activities were available.
Strongly
Disagree
1
INSTRUCTOR EVALUATION (Please circle your choice.)
1.
2.
3.
4.
5.
Gave safety guidelines and ensured that everyone followed
them at all times.
Demonstrated thorough knowledge of the subject matter.
Presented technical matter clearly.
Answered or followed up on all questions.
Provided enough time for practice.
Course Critique
Strongly
Disagree
Disagree
Neutral
Agree
Strongly
Agree
1
2
3
4
5
1
1
1
1
2
2
2
2
3
3
3
3
4
4
4
4
5
5
5
5
GENERAL INFORMATION (Please circle your choice.)
1.
The course length was just right.
Strongly
Disagree
1
Disagree
Neutral
Agree
2
3
4
Strongly
Agree
5
2. What did you like about the class? (Name at least two highlights.)
_________________________________________________________________________________
_________________________________________________________________________________
_________________________________________________________________________________
3. What would you change in the course to increase the quality of the training?
_________________________________________________________________________________
_________________________________________________________________________________
_________________________________________________________________________________
4. What, if any, were your expectations? (What did you want to learn?)
_________________________________________________________________________________
_________________________________________________________________________________
_________________________________________________________________________________
5. Did this class meet those expectations? Why or why not?
_________________________________________________________________________________
_________________________________________________________________________________
_________________________________________________________________________________
6. How will the completion of this course help you in doing your job?
_________________________________________________________________________________
_________________________________________________________________________________
_________________________________________________________________________________
7. Is there anything else that you would like to comment on that was not covered in this critique?
_________________________________________________________________________________
_________________________________________________________________________________
_________________________________________________________________________________
Thank you for completing this critique.
When you are finished, please turn this critique into your instructor.
Course Critique